OWNER`S MANUAL
SECTION: Z2.40.170
NOTICE TO INSTALLER: Instructions must remain with installation.
ZM2319
0515
Supersedes
0409
Your Peace of Mind is Our Top Priority ®
®
Product information presented
here reflects conditions at time
of publication. Consult factory
regarding discrepancies or
inconsistencies.
MAIL TO: P.O. BOX 16347 • Louisville, KY 40256-0347
SHIP TO: 3649 Cane Run Road • Louisville, KY 40211-1961
(502) 778-2731 • 1 (800) 928-PUMP • FAX (502) 774-3624
Register your
Zoeller Engineered Product
on our website:
http://reg.zoellerengprod.com/
visit our web site:
www.zoeller.com
OWNER’S MANUAL
69 HD SERIES SUBMERSIBLE UNITS
Congratulations on the purchase of the Zoeller 69 HD Series
submersible pump. For over sixty years the name Zoeller has
represented the standard for submersible dewatering and sewage
pumps. The same high quality workmanship and easy maintenance
design has been incorporated into this line of heavy-duty solidshandling submersible sewage pumps. This Zoeller pump will
provide years of trouble-free service when installed according to the
manufacturers’ recommendations.
This manual incorporates the installation, operation, maintenance,
and service instructions into one document to aid in the ownership
of a Zoeller submersible wastewater product. Please read and
review this manual before installing the product. Follow the steps
and procedures listed on ZM1074 for a proper start-up. Many items
contained within, when followed correctly, will not only ensure a long
and problem-free life for the pump, but also save time and money
during installation. Reference ZM2331 for repair manual on 69 HD
Series Pumps. Should further assistance be necessary please call
our Technical Service Department at 1-800-928-PUMP (7867).
Table of Contents
Safety Instructions
Safety Instructions........................................................................ 1
TO AVOID SERIOUS OR FATAL PERSONAL INJURY OR MAJOR
PROPERTY DAMAGE, READ AND FOLLOW ALL SAFETY
INSTRUCTIONS IN THIS MANUAL AND ON THE PUMP.
Limited Warranty........................................................................... 2
Preinstallation Information........................................................... 3
Electrical Data................................................................................ 3
Typical Dewatering Installation.................................................... 4
Typical Sewage Installation ......................................................... 4
THIS MANUAL IS INTENDED TO ASSIST IN THE INSTALLATION
AND OPERATION OF THIS UNIT AND MUST BE KEPT WITH
THE PUMP.
Pump Wiring Instructions..........................................................5-6
Operation.....................................................................................6-7
Maintenance................................................................................7-8
Service Checklist........................................................................... 8
Owner’s Information
Model Number: _______________ Date Code: _______________
Serial Number: Pump 1_____________ Pump 2_____________
Simplex Panel P/N ______________________________
Duplex Rail System P/N ________________________
Job Name: _____________________________________________
Distributor: ____________________________________________
Sales Order Number: ____________________________________
CAUTION
This is a SAFETY ALERT SYMBOL.
When you see this symbol on the pump or in the
manual, look for one of the following signal words
and be alert to the potential for personal injury or
property damage.
Warns of hazards that WILL cause serious personal
injury, death or major property damage.
Warns of hazards that CAN cause serious personal
injury, death or major property damage.
Warns of hazards that CAN cause personal injury
or property damage.
INDICATES SPECIAL INSTRUCTIONS WHICH ARE
VERY IMPORTANT AND MUST BE FOLLOWED.
THOROUGHLY REVIEW ALL INSTRUCTIONS AND WARNINGS
PRIOR TO PERFORMING ANY WORK ON THIS PUMP.
MAINTAIN ALL SAFETY DECALS.
Contractor: ____________________________________________
Date of Installation: ____________________________________
System Readings During Operation: Voltage _____ Amps ______
REFER TO WARRANTY ON PAGE 2.
© Copyright 2015 Zoeller® Co. All rights reserved.
Limited Warranty
Manufacturer warrants, to the purchaser and subsequent owner during the
warranty period, every new product to be free from defects in material and
workmanship under normal use and service, when properly used and maintained,
for a period of one year from date of purchase by the end user, or 18 months
from date of original manufacture of the product, whichever comes first. Parts
that fail within the warranty period, one year from date of purchase by the
end user, or 18 months from the date of original manufacture of the product,
whichever comes first, that inspections determine to be defective in material or
workmanship, will be repaired, replaced or remanufactured at Manufacturer's
option, provided however, that by so doing we will not be obligated to replace
an entire assembly, the entire mechanism or the complete unit. No allowance
will be made for shipping charges, damages, labor or other charges that may
occur due to product failure, repair or replacement.
This warranty does not apply to and there shall be no warranty for any material
or product that has been disassembled without prior approval of Manufacturer,
subjected to misuse, misapplication, neglect, alteration, accident or act of
God; that has not been installed, operated or maintained in accordance with
Manufacturer's installation instructions; that has been exposed to outside
substances including but not limited to the following: sand, gravel, cement,
mud, tar, hydrocarbons, hydrocarbon derivatives (oil, gasoline, solvents, etc.),
or other abrasive or corrosive substances, wash towels or feminine sanitary
products, etc. in all pumping applications. The warranty set out in the paragraph
above is in lieu of all other warranties expressed or implied; and we do not
authorize any representative or other person to assume for us any other liability
in connection with our products.
Contact Manufacturer at, 3649 Cane Run Road, Louisville, Kentucky 40211,
Attention: Customer Service Department to obtain any needed repair or
replacement of part(s) or additional information pertaining to our warranty.
MANUFACTURER EXPRESSLY DISCLAIMS LIABILITY FOR SPECIAL,
CONSEQUENTIALOR INCIDENTALDAMAGES OR BREACH OF EXPRESSED
OR IMPLIED WARRANTY; AND ANY IMPLIED WARRANTY OF FITNESS
FOR A PARTICULAR PURPOSE AND OF MERCHANTABILITY SHALL BE
LIMITED TO THE DURATION OF THE EXPRESSED WARRANTY.
Some states do not allow limitations on the duration of an implied warranty,
so the above limitation may not apply to you. Some states do not allow the
exclusion or limitation of incidental or consequential damages, so the above
limitation or exclusion may not apply to you.
This warranty gives you specific legal rights and you may also have other rights
which vary from state to state.
Each Zoeller 69 HD Series Pump installation is required to have a completed Zoeller Engineered Products Start-up Report (ZM1074). The report is to be completed
by an approved Start-up Technician in the presence of the installing contractor. A copy of this report will be on file at the Zoeller Engineered Products offices in
Louisville, KY, which will establish the start-up date.
© Copyright 2015 Zoeller® Co. All rights reserved.
2
Preinstallation Information
1. Inspect your pump. Occasionally, products are damaged during shipment. If the unit is damaged, contact your dealer before using. DO NOT remove the
oil fill plug in thrust bearing housing.
2. Carefully read the literature provided to familiarize yourself with specific details regarding installation and use. These materials should be retained for future
reference.
CAUTION
SEE BELOW FOR
LIST OF WARNINGS
1. Do not lift, carry, or hang pump by the electrical cables. Damage to the electrical
cables can cause shock, burns or death.
2.Make sure there is a properly grounded connection available. All pumps
are furnished with provisions for proper grounding to help protect you against
the possibility of electrical shock.
3. Make certain that the control box is within the reach of the pump’s power supply cord. DO NOT USE AN EXTENSION CORD. Extension cords that are too
long or too light do not deliver sufficient voltage to the pump motor. But, more
important, they could present a safety hazard if the insulation were to become
damaged or the connection end were to fall into the sump.
4.Make sure the pump electrical supply circuit is equipped with fuses and
disconnect or circuit breakers of proper capacity. A separate branch circuit is
recommended, sized according to the “National Electrical Code” for the current
shown on the pump nameplate.
5. C are should be taken during the initial installation to be sure that
adequate air supply is available whenever any person is in the basin. Always
follow OSHA guidelines on confined space requirements.
6.Risk of electric shock - These pumps have not been investigated for use in
swimming pool areas.
SEE BELOW FOR
LIST OF CAUTIONS
1. Check to be sure your power source is capable of handling the requirements
of the motor, as indicated on the pump nameplate.
2. The installation of pumps using auxiliary variable level float switches is the
responsibility of the installing party and care should be taken that the tethered
float switch will not hang up on the pump apparatus or pit peculiarities and is
secured so that the pump will shut off. It is recommended that rigid piping
and fittings be used.
3. INFORMATION - VENT HOLE PURPOSE. It is necessary that all submersible pumps capable of handling various sizes of solid waste be of the
bottom intake design to reduce clogging and seal failures. If a check valve
is incorporated in the installation, a vent hole (approx. 3/16”) must be drilled
in the discharge pipe below the check valve and pit cover to purge the unit
of trapped air. Water stream will be visible from this hole during pump run
periods. This vent hole should be checked periodically for clogging and
cleaned as necessary. Trapped air is caused by agitation and/or a dry
basin.
4. Water hammer creates momentary high pressure surges. These surges can
cause severe damage to check valves and the piping system. Consideration
for water hammer must be included in the piping system design. Reference
ASPE Data Book, Chapter 2.33. Some systems may require external spring
or lever weighted check valves or other engineered solutions.
5. Three phase pumps must be connected for proper rotation, which is
counterclockwise looking into impeller inlet. See page 4 for instructions for
checking 3 phase rotation.
Electrical Data
Frame
Size
210
250
320
360
*Consult Factory.
Amps
Full Load
Locked
Rotor
KVA
Code
Letter
60
52.6
262.2
F
3
60
26.3
131.1
F
230
3
60
62.8
344.2
F
460
3
60
31.4
172.1
F
Model
BHP
RPM
Voltage
Phase
Hertz
F6920
20
1725
230
3
G6920
20
1725
460
F6921
25
1725
G6921
25
1725
F6923
30
1725
230
3
60
74.6
434.4
G
G6923
30
1725
460
3
60
37.3
217.2
G
F6924
40
1725
230
3
60
99.2
546.0
F
G6924
40
1725
460
3
60
49.6
273.0
F
F6925
50
1725
230
3
60
128.0
690.0
F
G6925
50
1725
460
3
60
64.0
345.0
F
F6926
60
1725
230
3
60
142.0
756.0
F
G6926
60
1725
460
3
60
71.0
378.0
F
F6927
75
1725
230
3
60
174.0
1120.0
G
G6927
75
1725
460
3
60
87.0
560.0
G
F6928
100
1725
230
3
60
232.0
1524.0
G
G6928
100
1725
460
3
60
116.0
762.0
G
© Copyright 2015 Zoeller® Co. All rights reserved.
3
Typical Sewage/Waste Pumping System Installation
All installations must comply with all applicable electrical and plumbing codes, including, but not limited to, National Electric Code, local, regional,
and/or state plumbing codes, etc.
TYPICAL OUTDOOR CONCRETE BASIN WITH VALVE BOX AND HINGED ACCESS COVERS
3
7
4
4
7
16
1
10
8
10
2
13
14
9
11
NOTE: Maximum pump submergence not
to exceed 150 feet in depth and or 150 PSI
working pressure at motor lower seal.
6
XXXXXX-X
6
12
LOUISVILLE, KY.
15
ZEPA0592
(1) Electrical wiring and protection must be in accordance with the National
Electrical Code, and any other applicable state and local electrical requirements.
(2) Install proper full flow check and shut-off valve.
(3) Install proper controls. (Outdoor panels require NEMA 3R or 4X enclosure)
(10) Basin must be in accordance with all applicable codes
and specifications. Basin must be sized to allow a minimum 3 minute
lapse time between starts.
(4) All installations require a basin cover to prevent debris from falling into
the basin and to prevent accidental injury.
(11) Pump must be level and the tethered variable level float switch must
be free and not hang up on pump or pit peculiarities.
(5) Gas tight seals are required in all indoor sewage installations to
contain gases and odors.
(12)If a rail system is used, discharge elbow must be firmly anchored to
the bottom of basin. In fiberglass basin, the bottom will need to be
reinforced if the discharge elbow is used.
(6) When check valve is installed, drill a 3/16" diameter hole in the discharge
pipe below the check valve even with the top of the pump. NOTE: The hole
must be below the basin cover and cleaned periodically. Water stream
will be visible from this hole during pump run periods. Also a vent hole
is drilled in the pump housing. Be sure that this hole is cleared during
any servicing.
(7) Vent gases and odors to the atmosphere through vent pipe per Local
and State codes.
(8) Secure power cord to avoid entanglement with variable level float
switch mechanism.
(9) Do not reduce pump discharge pipe.
(13) Recommended guide rail material; stainless steel or galvanized
steel.
(14) Install ring and cable for lifting pump from pit.
(15) Basin must be clean and free of debris after installation.
(16) Cords must be properly sealed to prevent moisture and gases from
entering the control panel.
© Copyright 2015 Zoeller® Co. All rights reserved.
4
Pump Wiring Instructions
Installation and checking of electrical circuits and hardware should be performed by a qualified licensed electrician.
“Risk of electrical shock” Do not remove power supply cord and strain relief or connect conduit directly to the pump.
CAUTION
Power cords, sensor cords, and float cords all must be sealed to prevent gases from the basin entering the control panel.
INSTRUCTIONS FOR CHECKING ROTATION OF THREE PHASE UNITS
It is very important that these units be connected for proper rotation. Since no rotating parts are visible without removing the pump from the pit,
the rotation on 3 phase units should be checked before installation into the pit as follows:
After the proper electrical connections are made, momentarily energize the pump observing the direction of kick back due to starting torque. The rotation is
correct if the kick back is in the opposite direction of the rotation arrow. If the rotation is not correct, disconnect power and switch any two power leads. Turn
power back on and retest for proper rotation.
THERMAL SENSOR PROTECTION
Two thermal sensors and leads are wired adjacent to the motor windings. When the temperature exceeds the maximum recommended limit, the pump will
deactivate when the lead wires are connected to the magnetic starter circuit of a control panel with the thermal cutout feature. Continual deactivation of this
circuit requires attention from maintenance personnel (See Fig. 1). NOTE: If current through the thermostats exceeds the values listed in Table 1, an intermediate control circuit relay must be used to reduce the current or the thermostats will not work properly.
Table 1: Maximum Current Capacity of Motor Thermostat
Volts (VAC)
Continuous Amperes
Inrush Amperes
110-120
3.0
30
220-240
1.5
15
440-480
0.75
7.5
550-600
0.6
6.0
MOISTURE SENSORS
(1) Sensor cord conductors are connected to sensors probes in the lower cavity of the motor housing. The conductor wires are terminated in the control panel
for activating an indicator light when moisture is present in the lower cavity of the motor housing.
(2) When the moisture indicator light is activated, the lower seal has allowed leakage of water into the thrust bearing housing. The pump should be serviced
within 30 days to avoid damage to the motor and bearings.
(3) Oil in the thrust bearing housing must be checked when pump is serviced. If oil from the thrust bearing housing contains water or other contamination, both
seals should be replaced during maintenance. Always replace with new factory recommended oil and service parts. All warranty repairs must be made by
Zoeller Authorized Service Stations.
(4) Moisture sensor circuit can be checked for continuity (complete circuit) with a (Volt-OHM-Meter). Set the VOM to read resistance and connect the VOM
leads to the sensor cord red and orange wires. The VOM should read approximately 330k Ohms. Resistance readings significantly lower indicate a seal
leak with water in the motor housing chamber. If VOM reading is open then a problem exists with moisture sensor circuit.
Check resistance between the green ground conductor of the pump power cord and the sensor cord red and orange wires. This resistance reading should
indicate an open circuit. If VOM reading returns a reading other than open, then a problem exists with the sensor circuit wiring or cordage. If resistance
readings show a problem with either test, then pump should be repaired by a Zoeller Authorized Service Station (See Fig. 1).
CONTROL PANELS
These pumps are nonautomatic. They require a control panel. A motor starter circuit, control circuit, and alarm circuit within the panel are standard features.
Outdoor enclosures and alternating relays are often required. Variable level float switches are the most common level sensing device. The following should be
noted.
(1) A pump incorporating the seal failure sensor and thermal sensor protection require that interfacing terminals and functions be incorporated into the
panel.
(2) All pumps require overload protection in panel. Use with approved motor control that matches motor input in full load amperes with overload element(s)
selected or adjusted in accordance with control instructions.
(3) Hazardous Location pumps require panels that offer intrinsically safe relays and all other NEC requirements must be followed (See Article 500,501 & 502
plus any others that apply.)
POWER AND SENSOR CORD, LEAD IDENTIFICATION
BLACK
BLACK & WHITE
LEADS
TEMPERATURE
SENSOR
WHITE
RED & ORANGE
LEADS
SEAL FAILURE
SENSOR
RED
GREEN
GROUND
LEAD
4 LEAD SENSOR CORD
POWER
CORD
© Copyright 2015 Zoeller® Co. All rights reserved.
5
ZEPA0586
Three Phase Installation
Three phase pumps are nonautomatic. To operate automatically, a control panel
is required. Follow the instructions provided with the panel to wire the system.
Before installing a pump, check the pump rotation to insure that wiring has been
connected properly to power source, and that the green lead of power cord (See
wiring diagram), is connected to a valid ground, Momentarily energize the
pump, observing the directions of kick back due to starting torque. Rotation
is correct if kick back is in the opposite direction of rotation arrow on the
pump casing. If rotation is not correct, switching of any two power leads
other than ground, should provide the proper rotation.
Fig. 1 TYPICAL 3-PHASE WIRING DIAGRAM
3ø VAC
L1
L2
L3
T1
T2
T3
RECOMMENDED THERMAL SENSOR
CONNECTED IN SERIES WITH
STARTER COIL
W2 W1
POWER CABLE
BLACK
WHITE
RED
GREEN
P2 P1
WHITE
BLACK
SENSOR CABLE
ORANGE
RED
THERMAL SENSOR
(N/C)
SEAL FAILURE PROBES
330K OHMS RESISTANCE
3 PHASE MOTOR
SEAL FAILURE MOISTURE SENSOR
LEADS MUST BE CONNECTED TO
INDUCTION CIRCUIT IN THE CONTROL
PANEL.
HAZARDOUS LOCATION PUMP REQUIRE
THIS CONNECTION TO BE MADE TO AN
INTRINSICALLY SAFE RELAY
Refer to Sensor and Control Panel sections on page 5.
ZEPA0590
Operation
GENERAL
Zoeller pumps are lubricated and tested at the factory prior to shipment and
require minimum pre-start-up maintenance (Performance Test under submerged
condition optional).
Maximum continuous operating temperature of pump liquid for standard model
pumps must not exceed 104° F (40° C). For longest service life all pumps should
be totally submerged on long pumping cycles and a maximum of ½ hour run time
per hour.
These units are not designed to handle liquids other than water or sewage. If
pump is used in water contaminated with heavy, viscous, or abrasive materials,
the warranty will be voided.
NAMEPLATE DATA
The nameplate, located on the side of pump, indicates specific information about
the construction of the pump. The model number, date code, and serial number
information should be recorded on the front page in the “Owner’s Information”
section of this manual.
SHORT TERM STORAGE
If pump is to be stored, the following is advised:
• Store pump inside whenever possible or cover with some type of protective covering.
• Remove from crate and store in erect position in a protected area.
• Tape or seal in plastic bag the terminal ends of wire leads.
• Spray coat unpainted surfaces with rust inhibiting oil.
• The impeller should be rotated every 30 days in order to keep the seals
lubricated and not develop a permanent set.
If panel is to be stored, the following is advised:
• Store the panel inside whenever possible and leave in the shipping box.
• All openings shall be sealed.
• Store in an upright position.
• Do not stack anything on top of panel.
START-UP PROCEDURE
Before placing the equipment into operation, check the following:
• Correct pump rotation.
• Clean pit.
• Panel dry and securely installed.
• Floats positioned properly.
• Discharge valves open.
• 3/16” vent hole drilled in pipe between check valve and pump.
Once the above has been verified proceed with the following checks:
• Pump power cables properly connected to panel.
• Float cables properly connected to panel.
• Conduit connections to panel are properly sealed.
• Thermal overload adjustments made in the panel.
© Copyright 2015 Zoeller® Co. All rights reserved.
6
Operation (continued)
• After installing the pump into the containment area, with adequate
submergence, open the discharge valve fully. Start the unit using manual
controls. If flow is appreciably less than rated performance, pump may be
air locked. To expel trapped air, jog the unit several times, using the manual
controls.
• Have a qualified electrician take voltage and current measurements on
all three power wires of three phase with the pump running. Record these
readings in the space provided in the “Owner’s Information” section on
page 1 of this manual for future reference.
After the preoperational functional test has been completed, system is ready for
operation. Zoeller requires completing a Start-up Report (ZM1074) whenever a
system is started for the first time or after a system has had a significant change
take place (i.e. pump replacement, overhaul, etc.). A copy of the Start-up Report
should remain with the system for future reference.
ADJUSTMENT PROCEDURE
Pumps: No adjustments are required other than assuring correct rotation.
Panels: The thermal overloads in the panel must be set to the F.L.A. rating
on the pump nameplate (or refer to pump data sheet).
Floats: Refer to the system drawing for desired location of each float function.
Valves: Discharge valves should be placed in the fully open position. Systems should not be operated for extended periods of time with the
discharge valves partially closed due to damaging the valve.
SHUTDOWN PROCEDURES
If a system is shutdown for more than six months, the following is recommended:
Pumps: If pit is to remain dry, then the pump can remain in the pit. With the
pump in the pit, it should be operated for five minutes once every
three months. If the pit is to remain wet, the pump should be removed
and stored as noted above.
Panels: The panel should have all openings sealed to prevent moisture and dust
from entering the enclosure. Prior to restarting system, the panel should
be inspected for presence of moisture and any loose connections.
Valves: Consult the valve/actuator supplier for information concerning these
systems components.
Maintenance
Repair and service should be performed by a Zoeller Pump
Company Authorized Service Station only.
If pumps are to be stored for more than six months, refer to short term storage
procedure in the Operation section.
Repair and service of pumps with explosion proof motors must
be performed by a firm approved by Zoeller Company. The firm must be certified
to work on explosion proof motors if motor housing, thrust bearing housing or
cord cap is repaired. Contact Zoeller Technical Service Department regarding
warranty issues. If repair to the motor housing, thrust bearing housing or cord
cap is disassembled or repaired by a firm not certified to work on explosion
proof motors, the explosion proof rating is void and the FM approval tag MUST
BE REMOVED FROM THE PUMP.
PREVENTIVE MAINTENANCE
Preventive maintenance is recommended to ensure a long service life from the
product. Provided is a suggested maintenance schedule.
SAFETY PROCEDURES
For your protection, always disconnect pump and panel from
its power source before handling.
Never enter the basin until it has been properly vented and
tested. Any person entering a basin should be wearing a harness with safety
rope extending to the surface so that they can be pulled out in case of asphyxiation. Sewage water gives off methane and hydrogen sulfide gases, both of
which can be highly poisonous.
Installation and checking of electrical circuits and hardware should be performed
by a qualified electrician.
Pump is never to be lifted by power cord.
to servicing.
Unit must be flushed and disinfected, inside and out, prior
GENERAL SYSTEM INSPECTION
Before the system is placed into operation, a system Start-up Report should be
conducted by a qualified technician.
Wiring and grounding must be in accordance with the national
electrical code and all applicable local codes and ordinances.
LUBRICATION PROCEDURES
No lubrication is required.
Every month:
• Inspect float switches for any material that might be lodged and imparing
their operation.
• Listen for proper check valve operation.
• On duplex unit and if equipped with ET meters, check to see if elapsed time is
balanced between the two pumps. Any gross unbalance indicates a defective
unit, float switch or control.
• Inspect the panel for any presence of moisture in enclosure, loose connections,
and general component condition.
• Check moisture sensor circuit by means of the test button on the relay, or by
measuring the resistance of the moisture sensing circuit. Resistance should be
no less than 300,000 ohms.
Every year:
• In addition to the monthly checks, the basin should be inspected and cleaned.
Any defective components should be replaced. Inspect and remove any sand,
debris, or mud present in the pump basin assembly.
Every two years:
• Check insulating oil in thrust bearing housing.
• Inspect oil for contaminations. Milky, emulsified oil - Seals have failed. Unit
must be returned to an authorized service facility for service.
• Inspect power cables for damage or wear. Replace immediately if damage
or wear is detected.
• Inspect impeller for damage or wear. Replace as required by a Zoeller
Authorized Service Station.
• Drain, flush and refill the thrust bearing housing with new oil (properly dispose
of old insulating oil.) Refer to Maintenance Manual.
• Inspect power cable for any signs of abrasion or damage that might affect
the integrity of the outer jacketing.
• Inspect impeller and casing wear rings for unusual wear. Replace parts if
required.
© Copyright 2015 Zoeller® Co. All rights reserved.
7
Maintenance (continued)
Every five years:
• A complete overhaul by a competent service repair shop should include
the following:
• Completely dismantle the pump and motor.
• Clean and inspect all parts.
• Inspect all mechanical seal parts.
•
•
•
•
Replace worn or damaged parts.
Replace ball bearings regardless of condition.
Replace all “O” rings and gaskets.
Inspect motor stator for any sign of abrasion and burned spots on the winding.
Conduct an insulation test. Refer to the factory for values.
Service Checklist & Trouble Shooting
ELECTRICAL PRECAUTIONS Before servicing a pump, always shut off the main power breaker to the panel and then disconnect
the pump - making sure you are wearing insulated protective sole shoes and are not standing in water. Under flooded conditions, contact your local
electric company or a qualified licensed electrician for disconnecting electrical service prior to pump removal.
Submersible pumps contain oils which become pressurized and hot under operating conditions - allow 2½ hours after disconnecting before
attempting service.
CONDITION
A. Pump will not start or run.
Steps
No. 1
Check Voltage At
If No Voltage
If Voltage
Line terminals in pump’s
control panel
L1 - L2 - L3 (3 Phase)
Check Disconnect switch, line
fuse, and/or circuit breakers
in power supply circuit.
Proceed to No. 2
Check for control circuit
voltage. Check out magnetic
starter contacts, thermal
overloads, and float switches
Check pump for ground
and binding impeller
No. 2
Pump motor terminals in
pump’s control panel T1 - T2 - T3
COMMON CAUSES
B. Motor overheats and trips overload or blows fuse.
Incorrect Voltage; Unbalanced power source; Incorrect motor rotation; Negative or low
head; Excessive water temperature; Pump off Switch set too low; Impeller or seal
mechanically bound; Motor shorted; Lost one line in a Three Phase unit.
C. Pumps starts and stops too often.
Check valve stuck open; Level controls out of adjustment; Temperature sensor tripping;
Thermal overload switch out of adjustment or defective; Pit too small.
D. Pump will not shut off.
Debris under float switch; Float travel obstructed; Defective or damaged float switch;
Magnetic starter contacts shorted; Air lock - check vent hole.
E. Pump operates but delivers little or no water.
Check for plugged Pump housing, discharge pipe or sticking check valve; Vent hole
clogged or not drilled; Discharge head exceeds pumps capacity; Low or incorrect voltage
Incorrect motor rotation.
F. Drop in head and/or capacity after a period or use.
Increase Pipe Friction; Clogged line or check valve; Abrasive material & chemical,
deteriorated impeller and pump housing
If the above check list does not uncover the problem, consult the factory - Do not attempt to service or otherwise disassemble pump.
© Copyright 2015 Zoeller® Co. All rights reserved.
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